How to rewind Three-Phase induction stator.
How
to rewind Three-Phase induction stator.
Introduction:
Three-Phase induction
motor or asynchronous motor
is a 3 phase AC electric motor in which the electric
current in the rotor needed to produce torque is obtained by electromagnetic
induction from the magnetic field of the stator winding.
The course consists of
the following lessons:
Taking Data, Core Testing, Coil Cutoff, Burnout Procedures, Winding
Stripping Procedures, Core Preparation, Coil Making, Winding Insulation and
Coil Insertion, Internal Connections, Lacing and Bracing of Windings, Inspection
of Untreated Windings, Testing Untreated and Treated Windings, Winding
Treatment.
Tools and equipments;
Megger tester, cutter plier, a note book, oven, combination plier, insulators
papers.
Lesson
1:
Taking Data, the key
objective is to accurately determine winding data for a three phase stator,
including connection, turns, span(s), wire sizes, poles, and grouping; and core
and coil dimensions. It is important that the new winding data match the
original so that the motor produces the same performance characteristics (e.g.,
horsepower or kilowatt rating and speed) as prior to rewind, and that the
energy efficiency rating is maintained. Further, it is important to note that
some of the critical data cannot be determined later in the winding process.
For example, if the turns are not counted correctly, they cannot be determined
after disposing of the removed winding. Using a note book.
Lesson
2:
Core Testing, the main
objectives are how to perform a core test using two different methods, and the
materials and equipment needed. Another primary objective is recognizing the importance
of, and how to evaluate, the results of core testing. A properly performed core
test can detect core degradation prior to rewind. To achieve that, the core
should be tested before and after the burnout process. The key here is to avoid
inserting a new winding into a defective core, then having to repair the core
and repeat the rewind process, or worse, having to scrap the stator core. After
performing some core tests, the student should have a better understanding of
how much time and potential cost can be saved by performing core tests before
and after winding removal. Also, by performing the core testing, the student
will have a higher level of confidence that the stator core is in satisfactory
condition for rewinding. Using a megger tester
Lesson
3:
The critical objective
of the Coil Cut-off lesson is to be able to cut off coil extensions without
injury to the technician or the stator. Essentially the idea is to cut the
copper wire, not any other metal part of the stator, and to do it in a manner
that does not harm the stator or the person performing the task. Proper cutting
of the coil extensions also reduces time and effort when pulling the coils out.
Using a cutter plier.
Lesson
4:
Following the cutting
off of the coils, the next step is Burnout. Important objectives of the lesson
on the Burnout process are to understand how the burnout oven works in a
temperature-controlled manner, and how to operate and properly load the oven.
The burnout oven breaks down the winding insulation, to facilitate winding
removal. A key aspect of the burnout process is for the student to recognize
that control of the part temperature is much more critical to the process than
simply controlling chamber temperature.
Lesson
5:
The next step in the
rewind process is Winding Stripping. Primary objectives in this lesson are
understanding and using winding removal methods and equipment to remove the old
winding safely, and avoiding damage to the stator core. Because stripping
methods and equipment vary, the mentor should provide the student with specific
instructions on winding stripping in their service center. Closely associated
with Winding Stripping is Taking Data, as much of the important data is
obtained during the stripping process, e.g., connection, turns, span(s), wire
sizes, poles, and grouping. Note that this is a return to the data taking
lesson that began the winding process. Using combination plier.
Lesson
6:
After removal of the
windings and insulation, the bare core must be made ready for winding
insertion. Key objectives in Core Preparation are how to clean, inspect and
prepare the bare core; and how to repair lamination damage and defects. This
step assures that the core is in satisfactory condition prior to actual
rewinding, and is associated with the Core Testing lesson. The prepared core is
core tested to verify that core losses have not increased from the initial core
test by an unacceptable amount.
Lesson
7:
All of the steps and
associated lessons to this point have dealt with existing windings and stator
components. The first step in actual rewinding is Coil Making; that is,
creating new coils from new magnet wire and other materials. The primary
objectives of Coil Making are recognizing the materials, tools and equipment
needed; and how to make random wound coils to be installed into a three-phase
stator core.
Lesson
8:
Having made new coils,
they need to be inserted into the core, bringing up the next step, Winding
Insulation and Coil Insertion. The objectives of this lesson are to be able to
determine the materials and tools needed; and how to install random-wound coils
into a three-phase stator core. There are actually multiple steps in this
process, dealing with insulating and inserting. The slots are insulated, then
coils inserted, followed by insulating between coils
Lesson
9:
Even though the winding
coils have been made and inserted correctly, the winding will not perform
properly if it is not connected correctly. This is accomplished in the next
step, Internal Connections. In addition to requiring physical accuracy and
attention to detail, the student will learn the steps necessary to “lay out”
and verify the accuracy of the connection. Critical objectives of this lesson
are how to identify and lay out winding connections, and the procedures for actually
connecting the winding
Lesson
10:
The inserted winding
coils should be snug in the slots, but will need reinforcement to reduce the
tendency to move or shift. Varnish treatment and curing will do much to make
the winding more rigid; however, there is another key step to be used to
reinforce winding coils. That is Lacing and Bracing of Windings, with the main
objectives being to make the winder proficient in the methods, materials and
procedures for lacing and bracing of windings.
Lesson
11:
The next action step
for the winding is to treat and cure it. This step is essentially irreversible.
That is, the treated winding cannot easily be modified if, for example, the
connection is incorrect or there is a ground fault. Therefore the next steps in
the winding sequence are to inspect and to test the untreated winding. The
primary objective of Inspection of Untreated Windings is how to properly
inspect and evaluate an inserted and untreated three-phase random winding for
defects or imperfections.
Lesson
12:
Following inspection
the companion critical objectives of Testing of Untreated and Treated Windings
are how to perform and evaluate testing of untreated, and of treated,
three-phase random windings. The student receives information on the applicable
tests, how to perform them, and how to evaluate the results.
Lesson
13:
Following inspection
and testing of the untreated winding we move on to the final step in the
winding process, Winding Treatment. This step is crucial to providing a winding
with good heat transfer, high bond strength, and protection against
contamination. The key objectives of Winding Treatment are to make the winder
knowledgeable and proficient in the equipment and materials to varnish treat
and cure windings; and the methods and procedures to varnish treat, cure and
evaluate the finished three-phase random winding. The actual final step is
testing the treated winding, described above.
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